Flow rate measurement
When used in combination with an orifice plate assembly
(Type 90 Orifice Flange)...
Remote transmission of all relevant Media 6 data is possible using the Media MTM 32 hardware and the Media MTM 98 software.
for cryogenic. vapors and liquids (differential pressure method). 1 · Media 6
• Easy configuration using TROVIS-VIEW software
• Overloadable on one side up to the permissible static
pressure.g.Differential Pressure Meters
Media 6
Media 6 Z
Application
Microprocessor-controlled transmitter for measuring and
indicating the differential pressure or measured variables
derived from it · Suitable for gases or liquids · Measuring
ranges from 0.. but for hazardous areas · Input circuit
with type of protection
II 2 G EEx ia IIC T6
– Directly connectable valve block with test connection to
check the tank pressure and with connection for pressure
switch
Only with Media 6 Z
Associated Information Sheet
T 9500 EN
Edition July 2006
Data Sheet
T 9527 EN
.
the tank content (function of hydrostatic pressure. and vapors
• Microprocessor-controlled transmitter with RS-232 interface for configuration and programming on site
• Two adjustable software limit switches
• Gas selection by switch
• Programming via memory pen
• Digital display (LCD) for temperatures down to –40 °C
with 100 % bar graph as well as alarm and warning
markers
• Zero point and span adjustment activated via key without
influencing each other
• Two-wire connection for 4 to 20 mA signal
1)
Fig. supply voltage 12 to
36 V DC.
Special features
• Suitable for liquids.. tank geometry
data and liquid density of the stored gas) is converted into a 4 to
20 mA signal.
limit values can be monitored and indicated. in particular. the Media 6 devices can be used for
continuous flow measurement or counting the flow rate1) of
gases. The tank data can be transmitted via a phone line or GSM
to a remote PC. gases. SAMSON Type 5024-1) for the electric power supply
or the Media MTM 32 hardware for remote data transmission. consisting of:
LCD ø 90 mm with 100 % bar graph and blinking alarm and
warning markers · Two software limit switches or one software
limit switch acc. Additionally.3600 mbar · PN 50
Scope of application
– Liquid level measurements in pressure vessels. to NAMUR and a pulse output 1) · dp cell made
of CW617N (brass) or stainless steel · Free of oil and grease for
oxygen · Measuring ranges from 100 to 3600 mbar · ECO
measuring diaphragm · Zero point and span adjustment activated via key · Process connections G 3/8 A · RS-232 interface
Media 6 optionally available with:
– Version as above.100 to 0. which is proportional to the tank content and displayed on a LCD in the selected unit of measure. indicating unit with burst protection
• Field unit with degree of protection IP 65
• Digital display can be switched on or off by a switch
1)
• Eight-figure counting flow rate reading
• Pulse output proportional to quantity for external meter
1)
Versions
Media 6 with LCD · Transmitter with digital display · Two-wire
connection · Output signal 4 to 20 mA. where they are analyzed. liquefied gases
– Differential pressure measurements between the flow pipe
and return flow pipe
– Pressure drop measurements in valves and filters
– Flow rate measurement according to the differential pressure method
Liquid level measurement
When used in combination with an appropriate power supply
unit (e.

Principle of operation (Fig. 3)
The measuring device consists of a dp cell (1) with a measuring
diaphragm (1.1), range springs (1.2) designed to match the
span, and the indicating unit (7) with LCD.
The differential pressure $p= p1 – p2 causes a shift in the axis
(1.5) of the measuring diaphragm (1.1) supported by the range
springs (1.2). The change in travel, which is proportional to the
differential pressure, is transmitted by a lever (1.3) and the
flexible disk (1.4) out of the pressure chamber to the displacement sensor (2). This sensor converts the travel into an electric
signal.
The signal of the displacement sensor (2) is compared to the
data stored in the FRAM (4) and processed in the microprocessor (3). It controls both the LCD and the D/A converter (9) for the
output signal.
The output signal, which is proportional to the measured value,
is a load-independent direct current signal from 4 to 20 mA
issued at the connector A.
At the connector B, two software limit switches (8) for Alarm 1
(e.g. minimum filling level) and Alarm 2 (e.g maximum filling
level) are connected to the switching amplifier according to
EN 60947-5-6. A software limit switch (Alarm 1) and a pulse
output proportional to quantity (in place of Alarm 2) to operate
an external meter are used in Media 6 Z.

Indicating unit with LCD

9
Connector A

7
40

6

#

60

IA = 4 to 20 mA

80

20
m3

%

0

UB = 12 to 36 V
8
Connector B

100

Alarm 1
5

Alarm 2
3

MP

Pulse output 1)
RS-232
10
4

FRAM

dp cell
2
1.1

1.4
1.3
1.5

1.2

1.2

1

The RS-232 interface (10) enables the device to be configured
with a special memory pen or directly via a PC with SAMSON’s
TROVIS-VIEW Configuration and Operator Interface. The
user-specific data are saved in the data memory (FRAM) (4).
This way, a backup copy of the data can be saved until they are
overwritten. The operating data of the Media 6 can also be copied and loaded on site.

Valve block
with
pressure gauge

p2 _

p1 +

Four types of gas as well as the span and write protection function can be set at the DIL switch (6). In combination with three
keys (5), several operating functions (zero point and span adjustment, max. alarm limit switch and test function settings, etc.)
as well as the operating status (load/save operating values) can
be adjusted.

Electrical connection
In combination with a power supply unit (e.g. SAMSON
Type 5024) or the Media MTM 32 hardware, the tank content
can be transmitted and displayed over a 4 to 20 mA signal proportional to the tank content. In addition, the limits values can
be monitored and signalized.
Tank farm

Data can be transmitted either directly to the control room or, in
combination with Media MTM 32 hardware and Media
MTM 98 software over a phone line (analog/digital), or via radio signals to the PC of the gas supplier.

Control room

#

Control room

Data
transmission

Power supply
unit
e.g. Type 5024

Gas supplier

RS - 232
#

A

–
20

#

MTM 32

60

40

80
m3

0

%

100

A

B

Ar, N2, O2,
CO2, etc.

Power
supply
230 V AC

B

+
–

Switching amplifier
acc. to EN 60947-5-6

+

Switching amplifier acc. to EN 60947-5-6 PC with Media MTM 98
Two-wire circuit with data transmission to the control room

Terminal assignment
The Media 6 Differential Pressure Meter is designed for a two-wire
circuit. Both the 4 to 20 mA measuring signal and the required supply
voltage UB = 12 to 36 V DC for the two-wire transmitter are
transmitted by the same pair of wires.
The Media 6 is connected over a DIN 43650 connector, type 1,
4-pole.

Mounting
On mounting the Media 6, the following points must be observed:
– Attach it to a pipe, wall or mounting plate free of vibration.
– Use mounting part with clamp for pipe mounting to attach it
to a vertical or horizontal pipe.
– Use mounting part without clamp for wall mounting.
– See bottom diagram in Fig. 6 for control panel mounting.
We recommend installing a shut-off valve in each measuring
line as well as an equalizing valve. SAMSON provides for this
purpose a valve block designed as a compact unit (see
T 9555 EN) for direct connection to the Media 6 device.

8 µH

Maximum values only apply to the network connection to a certified intrinsically safe circuit.

Dimensions in mm
Mounting versions
Pipe mounting · With mounting device and clamp for attachment to
a vertical or horizontal 2” pipe.

Wall/panel mounting · Using two M8 tapped holes located at
the rear of the dp cell or two 8.3 mm holes in the valve block
(see diagram below).

Two 8.5 mm holes for fastening to rear side of the
dp cell (screws M8)
Two 8.5 mm holes for fastening
to rear side of the valve block (screws M8)

Fig. 6 · Dimensional diagram

5

T 9527 EN

Table 5 · Device configuration with ordering number
- Complete the order number with the order codes for the selected options Version

__

Type 5006–

__

__

__

__

__

__

__

Device
Media 6

1

Media 6 Z

2

Explosion protection
Without

0

EEx ia IIC T6*)

1

Display and output
LCD, 4 to 20 mA output

1

Material
Brass

0

Stainless steel

1

Measuring range
100 mbar

03

160 mbar*)

04

250 mbar

05

400 mbar*)

06

600 mbar*)

07

1000 mbar

08

1600 mbar*)

09

2500 mbar*)

10

3600 mbar*)

11

Diaphragm
ECO diaphragm (–40 to +80 °C)

0

NBR diaphragm (–30 to +80 °C)

2

Version acc. to specification sheet 1010-4300
Standard

00

Cryogenic gases (free of oil and grease for oxygen)

10

Paint compatibility and tobacco industry

50
000

Special version

Data logging
Data need to be made available about the tank characteristics
and the stored gas for the factory settings of the LCD reading
and the 4 to 20 mA signal to ensure that they are proportional
to the tank content and flow rate.

You can enter these data in the Specification Sheet for Media 6
parameterization.
A SAMSON Questionnaire for Flow Rate Measurement according to the Differential Pressure Method FB 9550 EN is available
to record the relevant data for flow rate measurement.
Accessories · Refer to T 9555 EN for accessories and details

remove the diaphragm from the spindle and unscrew the spindle approximately 10 mm from its guide.032. with a set pressure of 5 bar the relief pressure of the safety valve should not exceed 7. without notice. To remove the valve cone remove the spring cover
as described above. The spring should not be compressed
beyond the specified maximum pressure to avoid restricting the diaphragm movement or jamming the valve in open position. To do this the spring should be relaxed. Then all components should be reassembled and the valve checked for leaks. Manifolds.
REPL A CEMENT PA RTS
When ordering spare parts please provide the serial or catalogue number of the
product as well as the item number on the drawing and an accurate description of the part. s l i d i n g s u r f ac es an d t h r ead s w i t h g r eas e. As the outlet pressure increases above the pressure set via the setting screw.1. According to VDI/VDE Guideline 2174 a leakage rate of
0. Leakage or diaphragm damage is indicated by fluid escaping from the spring cover breather orifice. the valve closes. type 505 should be installed with its spring cover at the bottom
only for liquids and outlet pressures up to 1.
Pilot lines* should be connected at a distance of at least 10 times nominal bore downstream from the pressure reducer. the pressure reducer itself should be protected in such a way that 1.g.
The following procedure should be adopted in case of maintenance or repair: depressurise valve. remove spring cover.de
. the valve opens when the outlet pressure falls below the set pressure.de • e-mail: gm@mankenberg. a drain
line should be connected to the diaphragm housing breather orifice. The relief pressure
must. Renew the valve cone.5 bar.
INSTA L L A TION
Before installing the valve the pipeline should be flushed through thoroughly. e.451 . 99 • D-23556 Lübeck • Tel. In the case of steam installations operating at pressures below 0. The outlet
pressure may be increased temporarily by applying a light axial pressure to the setting screw. the spindle nut and clamp ring bolts should be fully tightened
whereas the spring cover screws should be torqued only gently to avoid crushing the diaphragm. relax spring.
COMMISSIONING
The pressure reducer has been tested for correct operation and leakage before despatch from the works. not exceed the rated pressure of the valve body.
MA INTENA NCE
Depending on the properties of the medium and the operating conditions of the system.8 79 75 99 • www. Remove any packaging material including
plastic plugs and install the valve into the pipeline ensuring that the arrow on the valve points in the direction of flow and the valve is free
of stress.mankenberg. Us e o n l y r ec o m m en d ed l u b r i c an t s f o r i n t er n al l u b r i c at i o n .2003
Mankenberg GmbH • Spenglerstr. Finally the outlet pressure should be set using the setting screw. +49 . If the leak persists the diaphragm
should be renewed as follows: unscrew spindle nut on diaphragm.1 bar and valve type 505Z
SA FETY DEVICES
Pressure reducers are not stop valves which provide a leak-proof shutoff function. be at the top or the bottom.
Pressure surges must be avoided. If necessary.OPERA TING INSTRUCTIONS
PRESSURE REDUCING VA L VE
TYPE 505
Sheet no. In case of jamming remove any high spots using fine emery cloth. Then lift the
spindle complete with its guide and cone (towards the bottom of the valve body) and withdraw completely past the seat towards the outlet. The diameter
should match the valve connection diameter. withdraw diaphragm disc and remove diaphragm together with its Oring (if fitted).
A strongly increasing outlet pressure at low flow rates indicates a defective cone seal. The valve is open when the pipeline is depressurised. When screwing the spindle back into its guide please make sure that the valve cone moves freely in its seat.
In addition the user must ensure that in the case of a diaphragm rupture any escaping fluid does not create a hazard. During commissioning the valve inlet should be opened slowly ensuring that the fluid drains from the outlet side. If coarse particles of dirt and foreign bodies cannot be avoided during operation. to alter or improve the designs or specifications of the products described herein.1 bar.
31..
Check control mechanism for freedom of movement.
1 Strainer*
2 Shut-off valve
3 Pr es s u r e Red u c er *
4 Safety valve*
5 Pressure gauge*
6 Control line G 1/4
7 Damping pot
*
use MANKENBERG products
Mankenberg reserves the right. The valve is supplied with the
spring relaxed.1
OPERA TION
The outlet pressure to be controlled exerts a force on the diaphragm which balances the load exerted by the spring in the normal operating state. +49 . the valve should be serviced and checked for correct functioning once a year or at shorter intervals. a strainer should be fitted.5 times the maximum set pressure is not exceeded.
DM 505/5.
Us e Par k er " Su p er -L u b e" t o l u b r i c at e EPDM O-r i n g s (Pl eas e n o t e: t h i s l u b r i c an t c o n t ai n s s i l i c o n e).1. Once the new diaphragm has been fitted complete with O-ring. stop valves or other restrictions immediately upstream or downstream from the valve should be avoided. The installation site should always be in a horizontal section of the pipeline that is not
subject to turbulence.03. the diaphragm should be checked. For this reason the German accident
prevention regulations VBG17 specify the installation of a safety device which prevents the maximum permitted system pressure being
exceeded.
Type 505Z should always be installed with the spring cover at the bottom.
IMPORTA NT: L u b r i c at e O-r i n g s . the spring cover removed and
the spindle nut tightened. The spring cover can.
*applies only to pressure settings up to 1. Unless otherwise specified. however. unless specified otherwise.05% of the constant volume flow value is permitted.451 . If a leak cannot be remedied by slightly tightening the
clamp ring or spring cover bolts.1 bar the pilot line should
be fitted with an expansion vessel. In the case of steam applications the control chamber should be filled with water via the pilot line connection before the
valve is commissioned.8 79 75 0 • Fax.

IMAT 4thGU-E
1) GENERAL
This instruction manual contains important information
regarding the installation, operation, maintenance and
storage for AIR TORQUE rack and pinion pneumatic actuators.
Please read these instructions carefully and keep them
for future reference. It is important that the use and
maintenance of the actuator is made only by properly
trained personnel.

m 2) WARNING

•

•

•

•

•

•

•

•

•

•

•
•
•

Do not operate the actuator using inflammable,
oxidizing, corrosive, explosive or unstable gases
or liquids (use only not dangerous fluids - group 2
according to 97/26/EC directive). Moreover, for
actuators installed in potentially explosive zones,
make sure that the internal parts of the actuator do
not come into contact with the external atmosphere.
Referring to the Machinery Directive 2006/46/EC,
the actuators can be classified as “PARTLY
COMPLETED MACHINERY” (see the DECLARATION
OF INCORPORATION). Therefore the actuator can
not put into service until the machinery and/or the
system, where the actuator is incorporated, will be
declared in compliance with the requirements of the
Directive 2006/42/EC.
Air Torque actuators are designed, produced and
classified according to the ATEX Directive 94/9/EC
(see actuator label and safety instructions). The use
of the actuators in potential explosive atmosphere
zones has to comply with the ATEX classification
indicated on the actuator label and according to the
ATEX safety instructions.
The use, the installation and the maintenance of
the Air Torque actuators must be made by adequately
trained personnel. For the use, installation and
maintenance of Air Torque actuators it is recommended to comply to the safety notice and to
use proper equipment to protect health and prevent
accidents.
It is important that the actuator is used only within
the working limits indicated in the technical specifications.
Do not operate the actuator over temperature limits:
this could damage internal and external components
(disassembly of spring return actuator may become
dangerous).
Do not operate the actuator over pressure limits: this
could damage internal parts as well as cause damage
to the housing and end-caps.
Do not use the actuator in corrosive environments
with incorrect protection: this could damage the
internal and external parts.
Do not disassemble individual spring cartridges, this
may result in personal injury. If maintenance to
springs is necessary, send them to AIR TORQUE.
Close and disconnect all air supply lines and make
sure that air connections are vented during maintenance and installation on valve.
Do not disassemble the actuator or remove end
caps while the actuator is pressurized.
The 4TH GENERATION Upgrade Series actuators are
designed to be used only on valves.
Before installing the actuator onto the valve make

•

sure that the rotation direction and the position
indicator are in the correct position.
If the actuator is incorporated in a system or used
within safety devices or circuits, the customer shall
ensure that the national and local safety laws and
regulations are observed.

3) WORKING CONDITIONS AND TECHNICAL DATA
• Operating media:
Dry or lubricated air or inert gases, provided that they
are compatible with the actuator internal parts and
lubricant. The operating media must have a dew point
equal to –20°C (-4°F) or at least 10°C below the ambient
temperature. The maximum particle size contained into
the operating media must not exceed 30 µm.
• Supply pressure:
The maximum supply pressure is 8 bar (116 Psi), only
for AT801U it is 7 bar (101,5 Psi).
For double acting and spring return actuators the working
pressure is from 2.5 bar (36 Psi) to 8 bar (116 Psi).
• Operating temperature:
==> “Standard” actuators from -40°C (-40°F) to +80°C
(+176°F)
==> Actuators for high temperature “HT” from -15°C
(+5°F) to +150°C (+300°F)
==> Actuators for extreme low temperature “LLT” from
-55°C (-67°F) to + 80°C (+176°F)
Caution: for low and high temperature service, special
grease and special components are required. Please
contact AIR TORQUE. Working at high or low temperature
can affect the life and the output torque of the actuator.
• Operating time (see technical data sheet):
Caution: the operating time depends on several factors
such as supply pressure, supply system capacity (pipe
diameter, flow capacity of pneumatic accessories), valve
type, valve torque and figures, applied safety factor,
cycle frequency, temperature, etc.
• Rotation and stroke adjustment (see technical data
sheet):
For standard actuators (90° rotation), 120° actuators
(120° rotation), 135° actuators (135° rotation) and 180°
actuators (180° rotation).
Stroke adjustment at 0°(closed pistons): +15°max/ - 5°.
Stroke adjustment at 90°, 120°, 135° and 180°(open
pistons): +5°/-15°max. For actuator AT045U the stroke
adjustment at 90° (open pistons) is available only on
request.
• Lubrication:
The actuators are factory lubricated for the life of the
actuator in normal working conditions.
The standard lubricant type GSTD is suitable for use
from -40°C (-40°F) to +80°C (+176°F).
For extreme low temperature (LLT) and high temperature
(HT) service, special grease is required: please contact
Air Torque.
• Construction: rack and pinion actuator design suitable
for both indoor or outdoor installations.
• Protection and corrosion resistance:
All the actuators are supplied with corrosion protection
for normal environments. For corrosion resistance of the
different types of protection see technical data sheet.
Before installing the actuator in aggressive environment,
ensure that the selected protection level is suitable.

3

GB
•

•

IMAT 4thGU-E

Actuator designation and marking (see technical data
sheets):
The actuator type, size, operating pressure, output
torque, direction of rotation, spring action, operating
temperature and type of connections/interfaces are
determined by designation.
All AIR TORQUE actuators are supplied with an identification label showing the serial number and all necessary
information on use, service, operation and product
designation. Where applicable, the label indicates the
classification according to ATEX Directive 94/9/EC.

4) OPERATING FUNCTION AND DIRECTION OF
ROTATION
The actuator is a pneumatic device for remote operation of industrial valves. The operation (90°,120°,135° or
180° rotation) may be activated by different methods:
• Direct mounting of solenoid valve (5/2 for double acting,
3/2 for spring return) to pressure connections 2 and 4,
connected to supply and control lines.
• Screwed connection (to pressure connections 2 and 4)
with air lines from separate control cabinet.
The standard rotation (when port 4 is pressurized or
for spring action) is clockwise to close. When port 2 is
pressurized, counter-clockwise rotation is obtained.
Air Torque actuators can be supplied with different types
of assembly/rotation direction depending on the type of
required operation and/or installation, see technical data
sheets.

Air supplied to Port “2” forces the pistons toward the actuator end caps,
compressing the springs.
A counter-clockwise rotation is achieved. Exhaust air exits from Port 4.

The loss of air pressure (air or electric failure) at Port “2” allows the springs
to force the pistons inward.
A clockwise rotation is achieved.
Exhaust air exits from Port 2.

Air supplied to port 2 forces the pistons towards the actuator end caps.
A counter-clockwise rotation is achieved.
Exhaust air exits from Port 4.

5) ACTUATOR INSTALLATION INSTRUCTIONS
The Air Torque actuator is a pneumatic device for the remote
operation of industrial valves. The actuator will operate through
90°,120°,135° and 180° rotation permitting the opening and
closing of many types of valves up to 180° rotation.
All the necessary technical information to install the actuator
correctly and safely onto a valve i.e.:
Dimensions, Output torque, Supply pressure, Air volume,
Stroke adjustment, Operating time, Operating temperature,
Direction of rotation and Weight is stated clearly on the
Actuator label, in the catalogue and technical data sheets.
Please read all technical information before proceeding with
the actuator installation.

m 5.1) Important safety notice!
•

•

•

•

•
Air supplied to Port 4 forces the pistons inward.
A clockwise rotation is achieved.
Exhaust air exits from Port 2.

4

For safety reasons, the actuator must not be pressurized
at any time during installation as injury may result.
The utmost cleanliness is required during air supply
connection to the actuator i.e. the connecting pipe
thread, fittings and seals must be clean and dirt-free.
When fitting accessories onto the actuators, assemble
them in such a way that the emergency control of the
solenoid valve and the top of the drive shaft are easily
accessible, should emergency manual operations be required.
Before fitting onto the valve, make sure that the actuator/
valve are correctly orientated, depending upon which
direction of rotation is required.
For spring return actuators, avoid that dangerous and/or
corrosive substances in the working environment enter
into the external chambers by using adequate filters
and/or solenoid valves.

GB

IMAT 4thGU-E
•

Remove plugs from actuator air connections during
installation and operation. Protect the air connections of
actuators not being used immediately.
5.2) Interfaces for actuator control and connections, figure A:

5.4) Assembly of valve figure C:
Before proceeding with the assembly of the actuator onto
the valve, be sure that the actuator operates in the desired
direction of rotation when pressurised and both actuator/
valve are in the correct position.

Important: when using a spring return actuator for a fail
safe operation, ensure that when air or electricity failure
occurs the direction of rotation is correct for your application.
Fit the actuator 3 onto the valve 5. It is possible to assemble
the valve onto the actuator in two ways:
Direct-mount: fit the stem of the valve 5 directly into the
female connection of the actuator 3 and bolt together
through the valve ISO pad (max. tightening torque see table).
Bracket-mount: mounting with a bracket 6 and coupling
7, the bracket is bolted to the actuator / valve to join
them together and the coupling is used to connect the
actuator output drive to the valve stem (max. tightening
torque see table).

Tightening torque table:

Fig. B

•

•

Solenoid valve mounting:
Before mounting a solenoid valve, ensure that the
actuator is in its normal position (closed position) with
pistons inwards.
For standard rotation type “ST” (clockwise to close)
assembly: the groove on the drive shaft or on the position
indicator 2 must be horizontal to the longitudinal axis of
the actuator in closed position.
Fit the solenoid valve 4 onto the actuator 3 using the
provided screws (max. tightening torque see table).
Switchbox mounting:
Fit the switchbox and bracket 1 onto the actuator 3 using
four provided screws (max. tightening torque see table).

6) MAINTENANCE INSTRUCTION
With the information given below, AIR TORQUE provides
the end user with all the required information necessary
for maintenance. Under normal conditions, the actuator
requires only periodic observation to ensure proper operation.
Maintenance (disassembly, maintenance and rebuilding)
of AIR TORQUE actuators is allowed only to AIR TORQUE
personnel or properly instructed personnel. In case of
controversy the product guarantee will expire!
Spare kits for maintenace are available to replace all
seals and bearings (soft parts indicated into the table),
that may be necessary between 300.000 and 1.000.000
cycles depending on operating and environmental
conditions and actuator size.

6.2) DISASSEMBLY
When disassembly of actuator is required for maintenance,
firstly remove the actuator from the valve. Before
performing any disassembly operations it is important
to verify that the actuator is not pressurised.
Always use caution and double check that the ports 2 and
4 are vented and are free from any accessory and/or
device. When the actuator is a spring return unit, make
sure that the actuator is in the failed position and with
pistons completely inwards before disassembling.
A) Removal of position indicator and graduated ring
(Part N° 19,19.0,19.1), figure 01:
•
•

•

Remove cap screw (39) if
fitted.
Lift position indicator (19
or 19.1) off shaft, it may
be necessary to pry gently
with a screwdriver.
Lift, if necessary, the
graduated ring (19.0)
off the body, it may be
necessary to pry gently
with a screwdriver.

Fig. 01

Fig. 03

•
•

Remove the o-rings (14) using a screwdriver. Discard soft
parts if replacing.
Only for actuators with adjustment 50% or 100%, remove
the nut 04R, the washers 03R and o-rings 11R and
discard soft parts if replacing.

D) Pistons disassembly (Part N° 40), figure 04:
• Holding the body (50) in a vice or similar device, rotate the
drive shaft (60) until the pistons (40) are released. Caution:
air pressure should not be used to remove the pistons from
the body.
• Remove o-rings (16) using a screwdriver. Remove the
piston back (05) and piston head (15) bearings.
• Discard bearings when replacing all soft components.

C) End caps disassembly (Part N° 30), figure 03:
• End caps disassembly for spring return actuators
(disassemble one end cap at a time).
Unscrew the end cap bolts (13) in the sequence shown in
figure 03, until the end-caps are free from springs force
(for AT045U and AT051U 20-23 turns of the screws, for
AT101U to AT801U 4-5 turns of the screws).
Then completely unscrew the screws and remove the
end-cap and the springs.
If there is still force on the end-caps after unscrewing as
indicated above, this may indicate that spring cartridge is
damaged or that the pistons are not completely closed,
so any further disassembly should be discontinued.
Further disassembly of the end caps may result in injury.
• End caps disassembly for double acting actuators
(disassemble one end cap at a time)
Unscrew the end cap bolts (13) in the sequence shown in
figure 03, until the screws are completely unscrewed and
the end caps are free.

8

E) Drive shaft disassembly (Part N° 60), figure 05:
• If necessary, remove the graduated ring (19.0) with a
screwdriver, remove the spring clip (18) using snap-ring
pliers or screwdriver for spiral rings, remove the thrust
washer (10) and the external thrust bearing (08). Apply
downward force to top of drive shaft (60), until it is partially
out of the bottom of the body when it is possible to
remove the internal thrust bearing (08) and the octi-cam
(01), then push the pinion (60) completely out of the
body. If pinion is not easily removed, gently tap the top
of the shaft with a plastic hammer.

Fig. 05

Fig. Install the
internal thrust bearing (08). it is possible to use lubricant
Dow Corning type Molykote® G-2003.
6. related to the bottom and top of the drive shaft and
the rotation of the actuator when energised. 09
For standard rotation assembly type “ST” (clockwise to
close).3) ASSEMBLY:
Prior to assembly. 07
and 07A:
•
•
Install top (06) and
bottom (07) bearings. 09.
• Grease the internal surface of the body (50) and the
piston (40) rack teeth. 06
•
•
Fit external thrust bearing (08). then
rotate the body anticlockwise from top view until the
stroke is completed. 07
•
•
Insert and press the two pistons (40) simultaneously
inside the body (50) until the pistons are engaged. 08
Fig. the rotation
obtained referred to the axis of the body is about over 0°
9
.
Ensure that with pistons completely closed. also replace the plugs (09).
• Insert the female connection of the drive shaft (60) in a
properly fixed coupling.
Fig. Insert completely the drive
shaft in the body. HT and LLT actuators) are
available in Air Torque.
Fig.
grease and insert the
bottom (20) and top
(21) pinion o-rings
onto the shaft.
Insert partially the drive shaft (60) in the body (50).
• the spare parts and the lubricant used are suitable for the
operating temperature of the actuator (see Air Torque
technical data sheets). 10 and 11:
• Grease and install o-rings (16).GB
IMAT 4thGU-E
•
•
Remove top (06) and bottom (07) pinion bearings and top
(20) and bottom (21) pinion o-rings. internal and external thrust
washer (08) and o-rings (20) and (21) if replacing the soft
components. figures 08.
install octi-cam (01) in the correct position (for standard
assembly or for lock-out) as shown in figures 07 and
07A. if necessary.
Only for “standard” actuators. piston back (05) and
piston head (15) bearings.
A) Drive shaft assembly (Part N° 60). for temperature from -40°C
(-40°F) to +80°C (+176°F). 07A
All the components disassembled and not replaced will
have to be cleaned and inspected for wear and before
reassembly.
• Ensure that the octi-cam is in the right position as shown
in figure 09.
•
B) Pistons assembly (Part N° 40).
Discard bearings (06) and (07). figures 06.
• Note: The lubricants suitable for the various operating
temperatures (Standard. rotate the body (50) about 40-45° clockwise from
top view. thrust washer (10) and then
external spring clip (18) using snap ring pliers or screwdriver
for spiral rings. 10
Fig.
Grease the outside
surface of the drive
shaft as shown in figure
06. as shown in figure 10. ensure that:
• all the components are perfectly clean and in good
condition.
Fig.

GB

IMAT 4thGU-E

for models AT051U→AT801U (0,5° over 0° for AT045U)
and that the dimension “A” on both sides is the same as
shown in figure 11.

AT051U configuration:
Side B

Fig. 11

Side A

Spring

AT051U

AT051U

AT051U

AT051U

Set

Internal

External

Internal

External

Spring type Spring type Spring type Spring type

C)
•
•
•

End cap (Part N° 30) assembly, figures 12, 13 and 14:
Assemble one end cap at a time.
Lubricate the body.
For spring return actuators, insert the springs in each
end cap according to the desired configuration, as shown
in figure 12 and related tables. For models
AT101U→AT801U insert spring cartridges as shown in
figure 13.

S1

1(green)

------------

------------

2 (black)

S2

------------

2 (black)

------------

2 (black)

S3

------------

2 (black)

------------

3 (red)

S4

------------

3 (red)

------------

3 (red)

S5

------------

3 (red)

1 (green)

2 (black)

S6

1 (green)

2 (black)

1 (green)

2 (black)

S7

1 (green)

2 (black)

1 (green)

3 (red)

S8

1 (green)

3 (red)

1 (green)

3 (red)

Fig. 13

•

Fit end cap o-ring seal (14) into the groove on both end caps.

Fig. 14
Fig. 12

•
•

SPRING SET CONFIGURATION
AT045U configuration:

•
Side B

Side A

AT045U

AT045U

Spring type

Spring type

S1-1

1 (green)

1 (green)

S1-2

1 (green)

2 (red)

S2-2

2 (red)

2 (red)

S2-3

2 (red)

3 (black)

S3-3

3 (black)

3 (black)

Spring Set

10

Fit end caps onto the body (50), verifying that the o-ring
remains in the groove.
Only for actuators with 50% or 100% stroke adjustment,
ensure that the adjustment screws 221G/222G are
completely screwed into the end-cap.
Insert the cap screws (13) and tighten each only partially.
Complete tightening by making 1-2 turns for each screw
in the sequence shown in figure 14 until tightening is
completed. See the table for screw tightening torque.

Stroke adjustment in close position: with the actuator in
close position 0°, screw or unscrew the right (from top
view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to
lock it in place.
Stroke adjustment in open position: with the actuator in
open position 90°, screw or unscrew the left (from top
view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to
lock it in place.
For spring return actuators, it could be necessary to make
rotation tests to verify the correct stroke adjustment in
open position.
Only for actuators with adjustment 50% or 100%, fit on
end-cap adjustment screws 221G/222G the o-rings 11R,
the washers 03R and the nuts 04R. To adjust the stroke
in open position: with the actuator in partially or totally
open position, screw or unscrew the end-cap adjustment
screw 221G/222G until the desired position is achieved. It
is important that the two end-cap adjustment screws are
both in contact with the pistons. Then lock the nuts 04R.

Fig. 15

Fig. 16

Fig. 18

Fig. 19

7) STORAGE INSTRUCTIONS
If the actuator is not for immediate use, the following
precaution must be taken for storage:
• Store the actuator in a clean and dry environment and at
temperature between –20°C (-4°F) and +40°C (+104°F).
• It is recommended that the actuator be stored in its
original box.
• Do not remove the plastic plugs on air supply ports.
8) LIFTING and HANDLING
It is recommended to lift the actuators with proper, adequate
and permitted systems in relation to the actuator weight and
by following the ruling laws in terms of safety and health
protection. The weight of the actuators is indicated on the Air
Torque catalogue and on the related technical data-sheets.
During the lifting and the handling of the actuators, it is
recommended to avoid clashes and/or accidental falls in
order to avoid irreparable damages to the actuators and to
compromise the functionality.
Contact Air Torque for any information and technical
data-sheets.

E) Assembly of graduated ring and position indicator
(Part N° 19,19.0,19.1), figures 17,18 and 19:
• Fix the graduated ring (19.0) to the body.
• If necessary, correctly position the “Top Adaptor” (19.5)
and lock it with the proper screws (19.6).
• Insert the indicator (19 or 19.1) making sure that it indicates
the correct actuator position.
• Screw the indicator screw (39) if assembled.

Operation instruction
GEROI ball valves are delivered in "open position". The ball-valves may only be stored in closed
storage rooms, in non-aggressive atmosphere and must be stored protected for damps and
contamination. Furthermore, please take care that the valves are not used for higher
temperatures and pressures as indicated. A guarantee for a certain period can only be granted
under these conditions. Only parts, underlying a natural wearing through corrosion, erosion etc.
are excluded. In case of a longer downtime the valves must be drained when you have frozen
mediums in use, and for expanded mediums you have to provide for a pressure balance. By
appearing leaks, the torques of the body or stem packing screws are to be checked according
table 1,2. In case of longer downtimes or only a few operations, we recommend a minimum use
of 6 x / year to increase the fatigue life.
table 1: tightening torque of the stem packing screw
size
1/4"
3/8"
½“
3/4"
1"
1 1/4"
1 ½“
2"
2 ½“
3"
4"

F30 may be
integrated into the line system in assembled condition.
putting into operation
Solids of any kind which are not components of the medium must be removed before the ball
valve is put into operation.
Mounting instruction
GEROI ball-valves may be integrated into the line system in whatever position desired.Generals:
GEROI ball-valves are suitable for gas and arc welding processes. however.2001
page 4 of 5
. must be in "open position". please disasemble the separator insert the body middle piece and fix with
the connecting bolts
* ball set to "closed position"
* body connecting bolts to be tightened with the indicated torques (table 2)
* performance check
Version 21. The
installation. to keep the
welding caps plane parallel during the welding process. that damages due to medium external particles
are not covered by the guarantee. We want to point out.
* connecting piece to be welded with the line system by an expert
* after cooling. please take care
that the line system is alignment truly axial at the sectioning part.5.
For that reason. The types S30. Furthermore.
* valve to be tacked with weld points into the line system
* body connecting bolts to be removed
* body middle piece to be taken out
* we recommend to screw in a separator of the same size as the body part. the vall valve must be dismounted before you start with the welding process. A tightness can only be
granted for weldings carried out by an expert.
How to install welded ball valves of type S30B
Due to the short overall length a too high temperature appears in the sealing element area during
the welding process.

out of the body or to be stripped from the
stem
All reusable parts. please hold
up at the stem over the interior of the body. please dismount one or two
screws. it must be taken out completely as the screw bolts can not
be dismounted under installed conditions.
To dismount a flange ball-valve. depending on the size. aline it centrical to the connecting piece introduce
missing connecting bolts and tighten them slightly
* tighten them with indicated torques
* performance check
change of stem packing
1) standard stem packing set:
* dismount the ball valve as described before (see change of seat)
* ball to be taken out of the body
* unscrew the hexagon screw of the stem. lift off the handle
* unscrew the second hexagon screw
* stem to be pressed in the body
* stem packing to be dismounted from outside
* PTFE disc for stem to be removed from inside.2001
page 5 of 5
.insert the ball and make a
90 ° twist (closed position-handle in 90 ° to tubular axle)
* installation of all other parts as described for the change of the sealing elements
* torques are indicated in table 1
Version 21. If necessary.change of the seat
* drain and depressurize the line system
* valve to set in "open position"
* unscrew the body connecting bolts. showing no damages are to be cleaned carefully.5.
* unscrew the hexagon screw
* set off handle and jam with a second nut
* dehedron of the stem to be turred in tubular axle for taking the ball .
* take out the body middle piece
* squeezing out the seat be turning the ball
* ball to set in "closed position"
* set new seats in the body adaption
* set body middle piece in origin position. Please renew defect parts
and assemble them as below:
* PTFE disc to be put over to stem (screwed side)
* stem to be taken in the drill of the stem packing from the inside of the body
* please insert the same quantity of stem packing rings stratified.

Do not tough the valve
directly. in non-aggressive atmosphere and must be stored
protected for damps and contamination. Then.
CAUTION
1.
5. When the valve is used at high temperature. the proper protection equipment. HCL and other
dangerous fluid.
for example anti-heating gloves. Any unsuitable operation action will cause the leaking or other problems. (any problem about for the used fluid. Only parts. But the pressure has to match the pressure
and temperature shown in the chart of pressure-temperature. The ball-valves may only be
stored in closed storage rooms. the first step is to turn of the pipe fluid and valve. please take care that the
valves are not used for higher temperatures and pressures as indicated.
Page 2 of 7
. and for expanded mediums you have to provide for a pressure balance. we
recommend a minimum use of 6 x / year to increase the fatigue life. If
that happens.
3.GEROI Ball valve – F 201
Edition 03-2006
OPERATING INSTRUCTION
GEROI ball valves are delivered in "open position". erosion etc. HF.
disassemble the valve.
underlying a natural wearing through corrosion. please contact the
manufactory). This valve is not used for unstable gases. be sure line pressure has been
relieved and any hazardous liquid. or steam is drained or purged from the
system. gas. In case of longer downtimes or only a few operations. 2. Before installing or performing maintenance. is highly suggested.
2. The principle is
that high temperature goes with low pressure. Furthermore. A guarantee
for a certain period can only be granted under these conditions.
4. The maximal temperature for our ball valve with the PTFE is 200° C the
minimum temperature is -23 C. By
appearing leaks. are excluded. In case of
a longer downtime the valves must be drained when you have frozen mediums in
use. Remember that different
temperature goes with different pressure. H2SO4. the torques of the body or stem packing screws are to be checked
according table 1.

or some other soft material to gently tap
the ball. replacement of all seats and
seals is recommend refer to service kit chart. adjustment nut. disc washer.
3.
Close the valve.
5. use a piece of wood. from the top into the valve body and remove it through the
end cap end of the body. Then remove the upper handle nut. This will unseat these parts without damaging the ball. and joint gasket. handle. heat may be required
If the ball.
4. if applicable.
1. do not fall from the body with the ball in the fully
closed position. end cap. and gland ring. thrust
washer. Press the stem.
Page 3 of 7
.
DISASSEMBLY
Note: If complete disassembly becomes necessary.
Routine maintenance consists of tightening the stem nut ¼ turn periodically to
compensate for the wear caused by the stem’s turning against the resilient PTFE
seal.GEROI Ball valve – F 201
Edition 03-2006
MAINTENANCE
Periodically observe the valve to be sure of proper performance more frequent
observation is recommend under extreme operating condition. and ball seat. Be very careful not to scratch any sealing surfaced in the
valve body ( surfaces on which seats and seal rest).
Unscrew and remove nuts.
Remove the stop washer. pry out and discard the old gland packing.
6. Using a pointed instrument.
2.

and do the same number of turning until all the nuts are finished. with the ball. tighten the
handle nut.
6. align the stem blade inside the valve body. and then do the
same number of turning to tighten every nut. trough the open end of the body. Insert the stem. Holding the trust washer. turn two opposite end diameter nuts of the flanged
end firstly. and handle nut. please reduce the leakage of the sealing. The raise face will
have the equal stress. plus an additional ¼ .
Page 4 of 7
. the gland ring.
8.
9. Place another wrench on the adjustment nut.
10. place the stop washer. and
rotate the stem. to the required torque. into the end cap. Screwed all bolts. with the flat surface on the bottom. handle. Cycle the valve slowly twice to ensure permanent position of the ball between
the two seats. in place from inside the valve. and threaded until the
stem starts to turn. drop in an ball seat.
3.
ASSEMBLY
1. Insert from the inside a trust washer. being careful not to scratch
thrust washer. Press it gently up into the stem hole.
5.
4. insert the ball. and turn down
until the seals bottom and the stem comes snugly in place tighten the gland
ring. see table for
body bolts torque specification.
2. Use
hands to tighten the spanner from 1 or 3 or 4 turning to the nuts. until snug and put the stop pin. and tighten the nuts. disc washer. over the stem. cover the end cap.GEROI Ball valve – F 201
Edition 03-2006
INSTALLATION
Install the raise face flanged end.½ turn. until snug. and thrust washer surface. into the lower stem bore. to the ball fully closed position. Place a wrench through the body on the bottom of the stem blade to hold the
stem stationary. Please refer to procedure repeats for
several times till the degree of the tightening meets your rewuest. and insert second ball seat. adjustment nut. Clamping valve body.
7. install three gland
packing. so that the
sealing surface of the seat is towards the ball insert the joint gasket. disc washer.

9
Tolerance (%)
+10
+10
+10
+10
+10
+10
+10
+10
+10
Page 5 of 7
.9
43.9
43. please dismount
one or two screws.1
10. it must be taken out completely as the screw
bolts can not be dismounted under installed conditions.
* take out the body middle piece
* squeezing out the seat be turning the
ball * ball to set in "closed position" * set
new seats in the body adaption
* set body middle piece in origin position.9
43.9
43.
To dismount a flange ball-valve. depending on the size.9
43. aline it centrical to the connecting
piece introduce missing connecting bolts and tighten them slightly
* tighten them with indicated torques
* performance check
Table 1: Tightening torque of the body cap (bolt and nut)
Size
1/2"
3/4"
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"
4"
Torque (Nm)
10.1
17.GEROI Ball valve – F 201
Edition 03-2006
CHANGE OF THE SEAT
* drain and depressurize the line system
* valve to set in "open position"
* unscrew the body connecting bolts.9
17.

* unscrew the hexagon screw
* set off handle and jam with a second nut
* dehedron of the stem to be turred in tubular axle for taking the ball . Please
renew defect parts and assemble them as below:
* PTFE disc to be put over to stem (screwed side)
* stem to be taken in the drill of the stem packing from the inside of the body
* please insert the same quantity of stem packing rings stratified.GEROI Ball valve – F 201
Edition 03-2006
CHANGE OF STEM PACKING
1) Standard stem packing set:
* dismount the ball valve as described before (see change of seat)
* ball to be taken out of the body
* unscrew the hexagon screw of the stem.insert the ball
and make a 90 ° twist (closed position-handle in 90 ° to tubular axle)
* installation of all other parts as described for the change of the sealing
elements * torques are indicated in table 1
Page 6 of 7
. lift off the handle
* unscrew the second hexagon screw
* stem to be pressed in the body
* stem packing to be dismounted from outside
* PTFE disc for stem to be removed from inside.
please hold up at the stem over the interior of the body. showing no damages are to be cleaned carefully. out of the body or to be stripped
from the
stem
All reusable parts. If necessary.

DANGER!
3YMBOLS
7ARNSÖOFÖAÖPOTENTIALLYÖDANGEROUSÖSITUATION
Failure to observe the warning may result in serious injuries or
death.
Ö
ENGLISH
→ÖDESIGNATESÖAÖPROCEDUREÖWHICHÖYOUÖMUSTÖCARRYÖOUT
REFERSÖTOÖINFORMATIONÖINÖTHESEÖOPERATINGÖINSTRUCTIONSÖORÖINÖ
OTHERÖDOCUMENTATION
7ARNSÖOFÖDAMAGEÖTOÖPROPERTY
Failure to observe the warning may result in damage to the device
or the equipment.
WARNING!
7ARNSÖOFÖANÖIMMEDIATEÖDANGER
Failure to observe the warning may result in a fatal or serious injury.
&AILUREÖ TOÖ OBSERVEÖ THESEÖ INSTRUCTIONSÖ MAYÖ RESULTÖ INÖ HAZARDOUSÖ
SITUATIONS
The operating instructions must be read and understood.
DESIGNATESÖADDITIONALÖSIGNIFICANTÖINFORMATION.

Correct transportation.ÖNEARBYÖEQUIPMENTÖANDÖTHEÖENVIRONMENTÖ
The device is designed for the controlled flow of liquid and
gaseous media. The designated
application cases are specified in the chapter entitled “Product
description”.
Use the device only as intended.
The device may be used only in conjunction with third-party devices
and components recommended and authorised by Bürkert. Operation is possible only in combination with a
suitable activation unit. correct storage and installation and careful
use and maintenance are essential for reliable and problem-free
operation. the operating conditions and conditions of
use specified in the contract documents.
Ö
0OSSIBLEÖERRORSÖINÖUSE
pÖ 4HEÖACTUATORÖHOUSINGÖMUSTÖNOTÖBEÖOPENEDÖ)FÖOPENED.
The admissible data. operating instructions and
on the rating plate are to be observed during use.

Supply the media connections only with those media which are
specified as flow media in the chapter entitled “Technical Data”.
Ö
)NTENDEDÖ5SE
4YPEÖ
.Ö$OÖNOTÖPAINTÖ
THEÖHOUSINGÖPARTSÖORÖSCREWS
Do not put any loads on the valve (e.ÖTHEREÖISÖAÖRISKÖ
OFÖINJURYÖFROMÖTHEÖTENSIONEDÖSPRINGÖINSIDE
Do not make any external modifications to the valves. by placing objects on it or
standing on it).g.

switch off the power supply and
secure to prevent reactivation!
Observe applicable accident prevention and safety regulations
for electrical equipment!
$ANGERÖkÖHIGHÖPRESSUREÖ
Before loosening the lines and valves.ÖTHEREÖISÖAÖRISKÖOFÖINJURYÖFROMÖTHEÖSPRINGÖJUMPINGÖOUT
The actuator housing must not be opened.
pÖ LOCALÖ SAFETYÖ REGULATIONSÖ THEÖ OPERATORÖ ISÖ RESPONSIBLEÖ FORÖ OBSERVINGÖ
THESEÖREGULATIONS. turn off the pressure and
vent the lines.
2ISKÖOFÖINJURYÖWHENÖOPENINGÖTHEÖACTUATORÖHOUSING
WARNING!
2ISKÖOFÖELECTRICÖSHOCK
Before reaching into the device.

After an interruption in the power supply or pneumatic supply.
'ENERALÖHAZARDOUSÖSITUATIONS
4HEÖSURFACEÖOFÖTHEÖDEVICEÖMAYÖBECOMEÖHOTÖDURINGÖLONG
TERMÖ
OPERATION
Do not touch the device with bare hands.ÖENSUREÖTHAT
the system cannot be activated unintentionally.
The general rules of technology apply to application planning and
operation of the device.
Installation and repair work may be carried out by authorised
technicians only and with the appropriate tools.
2ISKÖOFÖBURNS
CAUTION!
.
The device may be operated only when in perfect condition and
in consideration of the operating instructions.
ensure that the process is restarted in a defined or controlled
manner.

&ORÖCONTROLÖFUNCTIONÖ)ÖkÖ$ANGERÖIFÖCONTROLÖPRESSUREÖFAILS
WARNING!
3&"ÖÖ3&)
&IGÖÖ &
Ö LOWÖINLETÖUNDERÖSEATÖ
2ESTÖOPENCLOSED. first pressurise the device with
control pressure. then switch on the medium.ÖNOÖDEFINEDÖPOSITIONÖISÖREACHED
To ensure a controlled restart.

Following assembly. ensure a controlled restart.!4)/.
2ISKÖOFÖINJURYÖFROMÖIMPROPERÖINSTALLATION
Installation may be carried out by authorised technicians only and
with the appropriate tools!
WARNING!
2ISKÖOFÖINJURYÖDUEÖTOÖELECTRICALÖSHOCK
Before reaching into the device or the equipment.3AFETYÖINSTRUCTIONS
Ö
2ISKÖOFÖINJURYÖFROMÖUNINTENTIONALÖACTIVATIONÖOFÖTHEÖSYSTEMÖANDÖ
ANÖUNCONTROLLEDÖRESTART
Secure system from unintentional activation.
Ö
)NSTALLATION
4YPEÖ
"EFOREÖ)NSTALLATION
ENGLISH
2EMOVEÖACTUATORÖBEFOREÖWELDINGÖINÖTHEÖVALVEÖHOUSING
→Ö7ELDEDÖHOUSINGÖ
2EMOVEÖACTUATOR
→Ö3OCKETÖHOUSINGÖ
"EFOREÖTHEÖINSTALLATIONÖOFÖTHEÖHOUSING. turn off the pressure and
vent the lines..
DANGER!
).34!. switch off the
power supply and secure to prevent reactivation!
Observe applicable accident prevention and safety regulations
for electrical equipment!
$ANGERÖkÖHIGHÖPRESSUREÖINÖTHEÖEQUIPMENT
Before loosening the lines and valves.

first pressurise the device with
control pressure.
&ORÖCONTROLÖFUNCTIONÖ)ÖkÖ$ANGERÖIFÖCONTROLÖPRESSUREÖFAILS
WARNING!
.ÖNOÖDEFINEDÖPOSITIONÖISÖREACHED
To ensure a controlled restart. then switch on the medium.

Ö
)NSTALLATION
4YPEÖ
.
2ISKÖOFÖINJURYÖFROMÖUNSUITABLEÖCONNECTIONÖHOSES
WARNING!
$ANGERÖkÖHIGHÖPRESSUREÖINÖTHEÖEQUIPMENT
Before loosening the lines and valves. then switch on the medium. turn off the pressure and
vent the lines.
Observe the data sheet specifications from the hose manufacturers. first pressurise the device with
control pressure.ÖNOÖDEFINEDÖPOSITIONÖISÖREACHED
To ensure a controlled restart.
&ORÖCONTROLÖFUNCTIONÖ)ÖkÖ$ANGERÖIFÖCONTROLÖPRESSUREÖFAILS
(OSESÖWHICHÖCANNOTÖWITHSTANDÖTHEÖPRESSUREÖANDÖTEMPERATUREÖRANGEÖ
MAYÖRESULTÖINÖHAZARDOUSÖSITUATIONSÖÖ
Use only hoses which are authorised for the indicated pressure
and temperature range.

ensure a controlled restart. switch off the power supply and
secure to prevent reactivation!
Observe applicable accident prevention and safety regulations
for electrical equipment!
$ANGERÖkÖHIGHÖPRESSUREÖINÖTHEÖEQUIPMENT
Before loosening the lines and valves. never a pipe wrench.). turn off the pressure and
vent the lines. and observe tightening
torques.
Following maintenance. use an
open-end wrench.%!.
DANGER!
Ö 3AFETYÖINSTRUCTIONS
Ö
4YPEÖ
-AINTENANCE.
2ISKÖOFÖINJURYÖFROMÖIMPROPERÖMAINTENANCE
Maintenance may be performed by authorised technicians only!
To screw on or unscrew valve housing or actuator.Ö#.
WARNING!
2ISKÖOFÖINJURYÖDUEÖTOÖELECTRICALÖSHOCK
Before reaching into the system.'
2ISKÖOFÖINJURYÖFROMÖUNINTENTIONALÖACTIVATIONÖOFÖTHEÖSYSTEMÖANDÖ
ANÖUNCONTROLLEDÖRESTART
Secure system from unintentional activation.

&ORÖCONTROLÖFUNCTIONÖ)ÖkÖ$ANGERÖIFÖCONTROLÖPRESSUREÖFAILS
WARNING!
. then switch on the medium. first pressurise the device with
control pressure.ÖNOÖDEFINEDÖPOSITIONÖISÖREACHED
To ensure a controlled restart.

2ISKÖOFÖINJURYÖIFÖTHEÖWRONGÖTOOLSÖAREÖUSED
WARNING!
)TÖISÖDANGEROUSÖTOÖREMOVEÖAÖDEVICEÖWHICHÖISÖUNDERÖPRESSUREÖDUEÖTOÖ
THEÖSUDDENÖRELEASEÖOFÖPRESSUREÖORÖDISCHARGEÖOFÖMEDIUM
Before removing a device. switch off the pressure and vent the
lines. use an open-end
wrench.
2ISKÖOFÖINJURYÖFROMÖDISCHARGEÖOFÖMEDIUMÖANDÖPRESSURE
DANGER!
"EFOREÖTHEÖCONTROLÖCONEÖSETÖCANÖBEÖREPLACED.
ENGLISH
)TÖISÖDANGEROUSÖTOÖUSEÖUNSUITABLEÖTOOLSÖFORÖINSTALLATIONÖWORKÖASÖTHEÖ
DEVICEÖMAYÖBEÖDAMAGED
To remove the actuator from the valve housing. never a pipe wrench.

ÖTHEREÖISÖAÖRISKÖOFÖINJURYÖFROMÖTHEÖSPRINGÖJUMPINGÖOUT
The actuator housing must not be opened.
2ISKÖOFÖINJURYÖWHENÖOPENINGÖTHEÖACTUATORÖHOUSING
Ö
4YPEÖ
2EPLACEMENTÖPARTS
ENGLISH
7HENÖINSTALLINGÖAÖVALVEÖSEATÖWITHÖAÖMODIFIEDÖNOMINALÖWIDTH.

the conditions of use and the permitted data for positioner Type 8692 and Type 8693 which
are specified in the chapter entitled Technical Data in these
instructions and in the valve instructions for the respective
pneumatically actuated valve to ensure faultless operation
and long service life of the device.
and careful operation and maintenance are essential for
reliable and problem-free operation.
4
English
BASIC SAFETY INSTRUCTIONS
DANGER!
Risk of injury from high pressure.
• Observe the general rules of technology!
The positioner Type 8692 / Type 8693 was developed
with due consideration given to the accepted safety
rules and is state-of-the-art.
• The device must not be used outside.CORRECT USE
WARNING!
Incorrect use of the positioner Type 8692 and
Type 8693 can be dangerous to people.g.
Risk of electric shock when reaching into the equipment. dangers can
still arise.
• Do not make any external modifications to the device housings.
• Do not introduce any aggressive or flammable media into
the system's media connections.
• Before starting work.
• Do not introduce any liquids into the media connections.
• Do not put any loads on the housing (e.
• Use the positioner Type 8692 and Type 8693 only as
intended.
• The device must not be exposed to direct sunlight. always switch off the power supply
and safeguard to prevent re-activation!
• Observe applicable accident prevention and safety
regulations for electrical equipment!
WARNING!
Risk of injury from unintentional activation. and possibly its environment as
well. correct storage and installation. Failure to
observe these instructions and unauthorised tampering with
the device release us from any liability and also invalidate the
warranty covering the devices and accessories!
English
7
. Do not paint the housing parts or screws.
• Correct transportation.
• Take appropriate measures to prevent unintentional
activation!
6
English
English
5
WARNING!
Hazardous situations can arise during installation and
maintenance work.
• The device may be used only in conjunction with thirdparty devices and components recommended and authorised by Bürkert. by placing objects
on it or standing on it).
Forseeable Misuse
• The positioner Type 8692 and Type 8693 must not be used
in areas where there is a risk of explosion.
• Before loosening the lines and valves.
Operate the device only when it is in perfect condition and
in accordance with the operating instructions.
• In view of the wide range of possible application cases.
• This work may be carried out by authorised technicians
only and with the appropriate tools!
• After an interruption in the power supply or pneumatic
supply. ensure that the process is restarted in a defined
or controlled manner!
CAUTION!
The general rules of technology apply to applications
planning and operation of the device!
Failure to observe these rules may result in injuries and/
or damage to the device.
Follow the instructions. turn off the pressure and vent the lines!
Risk of electric shock. nearby equipment and the environment. However.
check whether the positioner is suitable for the specific
application case and check this out if required.

In the worst case scenario.
The positioner. make up
an optical and functional unit.10 111
Fax: 07940 . Slanted seat
valves. straight seat control valves.
And also on the internet at:
www.
If there are any discrepancies. please contact us immediately.
Positioners Type 8692 and Type 8693 are electropneumatic positioner controllers for pneumatically actuated control
valves with single-action or double-action drives.
Observe the requirements in accordance with EN 100015 – 1
to minimise or avoid the possibility of damage caused by
sudden electrostatic discharge. they will
be destroyed immediately or will fail after start-up.NOTICE!
GENERAL INFORMATION
Electrostatic sensitive components/modules!
The device contains electronic components which react
sensitively to electrostatic discharge (ESD).
Product Package
Check immediately upon receipt of delivery that the contents
are not damaged and that they correspond to the type and
quantity as indicated on the delivery note or packing list.
Process controller Type 8693
The positioner is integrated into a control loop. The position nominal value can
be specified by an external unit signal. together with the pneumatic drive.
Germany
Contact address:
Bürkert Fluid Control Systems
Sales Center
Chr.
Also ensure that electronic components do not come into
contact with a nearby power supply. The stroke
of the valve is calculated from the process nominal value
and the process actual value via the control parameters
(PID controller).10 448
E-mail: info@de.buerkert.com
8
Bürkert
English
Company
Locations
English
STRUCTURE AND FUNCTION
Position controller
Actuator drive
Valve
9
Functions
Position controller Type 8692
The position of the drive (stroke) is regulated according to
the position set-point value.: 07940 .
10
English
English
11
.-Bürkert-Str.
The control valve systems can be used for a wide range of
control tasks in fluid technology and. depending on the application conditions. different process valves from the Bürkert
range can be combined with the positioner.com
International
Contact addresses can be found on the final pages of
these operating instructions. diaphragm or ball valves
are suitable. The process set-point value can be set by
an external signal. 13-17
D-74653 Ingelfingen
Tel.burkert. Contact with
electrostatically charged persons or objects is hazardous
to these components.